Pattern drum for knitting machine



July 30, 1963 J. E. GARROU ETAL 3,099,145

PATTERN DRUM FOR KNITTING MACHINE Filed Aug. 9, 1961 20 INVENTORs: JAMES EZGARROU and Zffl VlCTOR H. GARROU. f1g4/ $-M,AM+W

ATTORNEYS United States Patent 3,099,145 PATTERN DRUM FOR KNITTING MACHINE James E. Garrou and Victor H. Gar-run, Valdese, N.C., assignors to Waldensian Hosiery Mills, Inc, Valdese, N.C., a corporation of North Carolina Filed Aug. 9, 1961, Ser. No. 130,361 5 Claims. (Cl. 66-154) This invention relates generally to pattern drums for knitting machines and more particularly to a unitary pattern element for use with pattern drums of the type which are mounted for step-by-step rotation and have an exterior pattern of irregular configuration which is engaged by levers or the like that control operation of the knitting machine instrumentali-ties in a predetermined timed relationship.

The unitary patter-n element of the present invention is primarily for use with pattern drums or trick wheels which are used on Hemphill type circular hosiery knitting machines. This type of pattern drum includes a cylindrical mandrel which has a ratchet wheel attached to one end and a plurality of circular pattern disks and spacers stacked in alternation on the mandrel. Each of the pattern disks has outwardly projecting frangible pattern butts on the outer periphery. It is the conventional practice to manually remove certain butts on each pattern disk, in accordance with the particular pattern requirements, and then place the pattern disks on the mandrel in the proper order to form the exterior surface of the pattern drum and provide raised pattern areas and pattern relief areas thereon.

There are one or more of these pattern drums on each knitting machine and when it is desired to set up several machines to knit the same pattern, identical pattern drums must be made up for each machine. A skilled operator is required to remove the proper butts from the pattern disks and stack them in the proper order to provide the desired pattern configuration on the exterior of the pattern drum. This is a time-consuming operation and is relatively expensive since the pattern disks cannot normally be re-used when the pattern on the drum is revised.

Normally, when a new pattern is to be knit on the machine, the stack of pattenn disks are removed from the mandrel and tied together for storage so that they may be used again, if the same pattern is again desired. The stored pattern disks are subject to rust and corrosion and the pattern disks may become disarranged and cause knitting errors after reinstallation of the disks on the knitting machine. Also, when the same pattern is to be knit on a plurality of machines, it is difficult to repeat the butt arrangement on the various disks 2. great number of times without making errors.

In an attempt to overcome the culties encountered in forming pattern drums of stacked pattern disks, various types of pattern drums have been made which have ci-rcumferentially spaced pattern elements that are supported for independent inward and outward radial adjustment. In this type of pattern drum, pattern disks are not required and the raised and relief pattern areas are fonned by moving the pattern elements inward and outward and the elements may be arranged in any desired manner so that the pattern drum may be used to knit any desired pattern. However, the radial -adjust ment of the individual pattern elements is very timeconsuming and is subject to human errors, each time that one of the pattern elements is radially adjusted. Also, when the pattern on this type of drum is changed, the original pattern is lost and if it is desired to again knit the original pattern, the pattern elements must be again arranged in the original order.

With the foregoing in mind, it is a primary object of the present invention to provide a unitary cylindrical pat- :above-mentioned diffitern element having integrally formed raised and relief pattern areas on the exterior surface and which pattern element may be economically produced to conform to any particular pattern requirements.

It is a more specific object of the present invention to provide -a unitary pattern element for knitting machine pattern drums of the type which include a cylindrical mandrel and a ratchet wheel secured to one end of the mandrel for imparting step by-step rotation to the mandrel, the pattern element being in the form of a sleeve which is supported on the mandrel for rotation therewith and the exterior of the sleeve having an integrally formed pattern configuration of raised pattern areas and pattern relief areas.

It is another specific object of the present invention to provide a pattern element of the type described wherein the sleeve is formed by casting or molding plastic material whereby a plurality of identical pattern elements may be economically formed from a single mold or pattern and the pattern element will not rust or corrode during storage or in use.

It is a further object of the present invention to provide a pattern element of the type described which may be easily replaced on the knitting machine and which can be stored for future reuse without any danger of :rearrang' ing or disturbing the pattern arrangement thereon.

Some of the objects of the invention having been stated, other objects will appear as the description proceeds, when taken in connection with the accompanying drawings, in Which-- FIGURE 1 is an exploded isometric view showing the various component parts of an improved pattern drum formed in accordance with the present invention and with the surfaces of the raised and pattern relief areas of the pattern element sleeve being smooth;

FIGURE 2 is an enlarged front elevation of the unitary pattern element sleeve of the present invention, with the raised pattern area having an irregular surface simulating the appearance of horizontally and vertically alined pattern butts and the pattern relief area having an irregular surface simulating the appearance of broken-off pattern butts, the lines simulating the irregular surfaces adjacent the juncture of the raised pattern area and the pattern relief area being omitted to clearly illustrate the stepped configuration of the edge of the raised pattern area;

FIGURE 3 is a top plan view of the unitary pattern element sleeve shown in FIGURE 2;

FIGURE 4 is a vertical sectional view through the pattern element sleeve, taken substantially along the line 4-4 in FIGURE 2.

Referring particularly to FIGURE 1 of the drawings, there is shown a pattern drum for use on circular knitting machines which includes a cylindrical hub or mandrel It) having a ratchet wheel 11 suitably secured to the lower end thereof. The ratchet wheel 11 is provided with ratchet teeth which are engaged by a reciprocating pawl, not shown, to impart step-by-step rotation to the drum in timed relationship to operation of the knitting machine, in a conventional manner. The mandrel 10 is provided with a keyway in which a key 12 is suitably secured. The mandrel 10 has a centrally disposed bore 13 which is adapted to receive a shaft 14 that is in turn supported at its lower end on the frame of the circular knitting machine in a conventional manner.

Ordinarily, a plurality of thin metal pattern disks and spacer rings are alternately placed on the mandrel 10. Each of the pattern disks has a keyway cut in the inner periphery and radially projecting flangible pattern ele ments or butts on the outer periphery. Certain of the butts of each pattern disk are broken off, in accordance with the particular pattern desired, and the disks are placed on the mandrel in predetermined order to provide raised and pattern relief areas on the exterior of the drum. Then, a ring and a cap member 16 are secured to the upper end of the mandrel It) by screws 17 to clamp the pattern disks and spacer rings together and prevent any vertical movement on the mandrel It). A conventional braking device 20 is suitably supported on the upper end of the shaft 14 and has friction elements 21 supported therein. The lower ends of the friction elements 21 engage the upper surface of the cap member 16 and provide a braking action to prevent free rotation of the mandrel 10 and associated parts as it is racked in a step-by-step manner.

The foregoing parts are conventional parts of a pattern drum of the type currently used on a Hemphill type circular knitting machine and it is with this type of pattern drum that the present invention is primarily concerned. However, it is to be understood that the unitary pattern element disclosed herein may also be utilized to provide raised and relief pattern areas on other types of knitting machine pattern drums, trick wheels and the like.

In accordance with the present invention, a one-piece or unitary pattern element, broadly indicated at :25, takes the place of the stack of individual pattern disks and spacers which have heretofore been employed to form the raised and relief pattern areas of the pattern drum. The pattern element 25 is shown in the form of a sleeve or hollow tubular member which has a longitudinal bore or opening 26 extending from one end to the other. The diameter of the bore 26 is substantially the same as the outside diameter of the mandrel 1t) and a keyway 27 is provided so that the pattern element 25 may be easily slid onto and off of the mandrel 1t and will rotate therewith. The length of the pattern element 25 is substantially the same as the length of the mandrel 10 and when the pattern element 25 is positioned on the mandrel It), the ring 15 and cap member 16 prevent longitudinal or vertical movement thereon.

As shown in FIGURES 1, 2 and 4, the exterior surface of the pattern element 25 has a pattern of predetermined configuration thereon which includes raised pattern areas 30 and pattern relief areas 31. As is clearly shown in FIGURE 4, the raised pattern areas 30 and the pattern relief areas 31 are formed integral with the pattern element sleeve 25.

The unitary pattern element sleeve 25 may be formed in any suitable manner and of any type of suitable material. However, it is preferred that the sleeve be formed by molding or casting a suitable plastic material of thermosetting resin, such as epoxy resin. A pattern drum formed of a plurality of stacked pattern disks may be used to first obtain a female master pattern mold, which is a mirror image of the pattern drum. After the master pattern mold is obtained, any desired number of identical pattern elements 25 can be economically produced therefrom and the pattern mold can be stored and again used to produce additional pattern elements, when desired.

It will be noted particularly in FIGURE 2 that the outer periphery of the pattern element sleeve 25 has the same appearance as a group of stacked individual pattern disks and spacers and this appearance is obtained because the plastic sleeve 25 has been formed from a pattern mold which was made from a conventional pattern drum formed with alternating pattern disks and spacers. However, it is to be understood that the surfaces of the raised pattern areas 30 and the pattern relief areas 31 could be made smooth, as shown in FIGURE 1. In this case, the small spaces between the full and broken butts of the master pattern drum are filled with clay or putty before the pattern mold is formed therefrom. Then the inside of the pattern mold and the outside of the molded pattern element 25 is smooth, as shown in FIGURE 1.

When the pattern element sleeve 25 is formed of molded plastic, there is no danger of rust or corrosion while the sleeve is in operation on the knitting machine nor while the same is stored. Also, the unitary pattern A. sleeve 25 may be put on and taken off of the machine without any danger of disturbing the pattern thereon and this is not true of the individual pattern disks and spacers, since they may become disarranged.

The unitary pattern element 25 may be easily exchanged for another pattern element, having a different arrangement of raised pattern areas and pattern relief areas, simply by removing the tension device '20, the cap 16 and ring 15. Then, the sleeve 25 may be lifted off of the mandrel 1t) and replaced by another sleeve 25 which has a different pattern arrangement thereon. The ring 15, cap 16 and the tension device 20 may then be replaced and the pattern drum is ready for operation.

In some types of circular knitting machines, such as the Hemphill SCP and 500? type knitting machines, four pattern drums are used on each machine and usually a plurality of knitting machines are set up to knit the same pattern. When it is desired to change the pattern being knit by the machines, it is only necessary that one master pattern drum be formed and then any desired number of pattern element sleeves 25 can the cast from a single pattern mold produced by the master pattern drum. Since a plurality of pattern sleeves 25 may be cast from a single pattern drum and mold, the per unit cost, from both a labor and material standpoint, is much cheaper than in the old method Where each pattern drum was formed by breaking the butts from individual pattern disks and arranging them in the proper order.

Errors in forming the pattern surfaces on the pattern drums are eliminated after the proper formation of the master pattern drum and the unitary construction of the pattern sleeve 25 enables quick and accurate installation on the knitting machine. The pattern mold may be stored and, if it is decided to set up additional knitting machines on the same pattern, additional pattern element sleeves 25 may be quickly and economically cast from the original pattern mold.

In the drawings and specification there has been set forth a preferred embodiment of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.

We claim:

1. In a pattern drum for knitting machines having a cylindrical mandrel and a ratchet wheel secured to one end of the mandrel for imparting step-by-step rotation to the mandrel, the combination therewith of a one-piece pattern sleeve surrounding and supported on said mandrel for rotation therewith, said pattern sleeve being of substantially the same length as said mandrel, and an integral pattern of predetermined configuration on the exterior of said sleeve, said pattern configuration including raised pattern areas and pattern relief areas.

2. In a pattern drum for knitting machines having a cylindrical mandrel, said mandrel having a keyway extending longitudinally thereof, a key positioned in the keyway and extending outwardly therefrom, and a ratchet wheel secured to one end of the mandrel for imparting step-by-step rotation to the mandrel, the combination therewith of a one-piece pattern sleeve surrounding and supported on said mandrel, said pattern sleeve being of substantially the same length as said mandrel and having a longitudinally extending keyway on the interior surface, said key extending into the keyway of said sleeve to prevent rota ion of said sleeve on said mandrel, and an integral pattern of predetermined configuration on the exterior of said sleeve, said pattern configuration including raised pattern areas and pattern relief areas.

3. In a pattern drum for knitting machines having a cylindrical mandrel and a ratchet wheel secured to one end of the mandrel for imparting step-by-step notation to the mandrel, the combination therewith of a one-piece molded plastic pattern sleeve surrounding and supported on said mandrel for rotation therewith, said pattern sleeve being of substantially the same length as said mandrel, and an integral pattern of predetermined configuration on the exterior of said sleeve, said pattern configuration including raised pattern areas and pattern relief areas.

4. In a pattern drum for knitting machines having a cylindrical mandrel and a ratchet wheel secured to one end of the mandrel for imparting step-by-step rotation to the mandrel, the combination therewith of a one-piece molded plastic pattern sleeve surrounding and supported on said mandrel for rotation therewith, said pattern sleeve being of substantially the same length as said mandrel, an integral pattern of predetermined configuration on the exterior of said sleeve, said pattern configuration including raised pattern areas and pattern relief areas, and the exter-ior surfaces of the raised pattern areas and pattern re lief areas being smooth.

5. A pattern device for use on knitting machines comprising a one-piece plastic pattern element, said element being cylindrical and having an integrally formed pattern of predetermined configuration on the exterior thereof, said pattern configuration inoluding raised pattern areas and pattern relief areas, and said pattern element being in the form of a sleeve having an uninterrupted hollow bore therethrough.

References Cited in the file of this patent UNITED STATES PATENTS 1,896,431 Steere Feb. 7, 1933 2,805,563 Brewer et al Sept. 10, 1957 FOREIGN PATENTS 202,448 Great Britain Aug. 23, 1923 

1. IN A PATTERN DRUM FOR KNITTING MACHINES HAVING A CYLINDRICAL MANDREL AND A RATCHET WHEEL SECURED TO ONE END OF THE MANDREL FOR IMPARTING STEP-BY-STEP ROTATION TO THE MANDREL, THE COMBINATION THEREWITH OF A ONE-PIECE PATTERN SLEEVE SURROUNDING AND SUPPORTED ON SAID MANDREL FOR ROTATING THEREWITH, SAID PATTERN SLEEVE BEING OF SUBSTANTIALLY THE SAME LENGTH AS SAID MANDREL, AND AN INTEGRAL PATTERN OF PREDETERMINED CONFIGURATION ON THE EXTERIOR OF 